Waterproof membrane with cross-laminated film

ABSTRACT

A waterproof extrusion laminated flexible membrane that may be seamlessly applied to an irregularity on a substrate supporting a finished surface for waterproofing that includes first and second polypropylene non-woven layers each having first and second surfaces, a water impermeable HDPE oriented cross laminated film layer, a first tie layer between the first non-woven first surface and the cross laminated film layer, and a second tie layer between the second non-woven first surface and the cross laminated film layer. Other membranes and methods are also disclosed.

CROSS-REFERENCE TO RELATED APPLICATION DATA

The present application is a continuation of U.S. patent application Ser. No. 14/305,366 filed on Jun. 16, 2014, the disclosure of which is incorporated herein by reference in its entirety, and which claims the benefit of and priority to Provisional Application Ser. No. 61/836,750, filed Jun. 19, 2013, the disclosure of which is incorporated herein by reference in its entirety.

BACKGROUND

The ability to effectively waterproof a building structure such as a wall or floor is extremely important. Waterproofing is important to prevent moisture incursion into, and degradation of, the underlying substrate and structure.

In one example, a waterproof surface is required between tile and an underlying substrate (e.g., walls or floor) and the supporting structure, (e.g., studs), in bathrooms, showers and the like where wet environments and moisture and/or water incursion may occur. Water will often seep behind tile walls or underneath floors, through grout, and into the wall or floor substrate. If the underlying substrate is formed from a water resistant or perhaps even a waterproof material, potential damage to the substrate and the underlying structure is minimized. For example, cement board or water resistant gypsum wall board are often used as a substrate in showers and the like.

However, such materials are not inherently waterproof and may be subject to degradation over time. Moreover, in use, board-formed materials may be cut and seams used where boards are placed together, such as along extended surfaces, at comers, around openings and the like, which exacerbates the potential for water incursion and degradation. As such, water and/or moisture incursion into the substrate, or though the substrate and into the underlying structure may occur unless these substrates arc protected across their entire surfaces with a waterproof clement.

Other materials are also known. For example, KERDI-BOARD, commercially available from Schluter is multi-component, waterproof board for use in areas that may be subjected to high moisture. However, because they are rigid members that may require seams and cuts to accommodate long stretches of surface, comers and the like, the seams and penetrations must be treated with a waterproof element.

Accordingly, there is a need for a waterproof element for use in high moisture environments in new construction, remodeling and retrofits. Desirably, such an element is flexible and in sheet or roll form. More desirably still, such an element is formed as a membrane, is sufficiently flexible to permit use in comers, curved areas and the like, without scams and joints. Still more desirably, such a material is sufficiently strong, e.g., high strength, to prevent tears and punctures when used at, for example, construction sites.

SUMMARY

A membrane includes a first non-woven layer having first and second surfaces, a cross laminated film layer, a second non-woven layer having first and second surfaces and a tie layer between the first non-woven first surface and the cross laminated film and the second non-woven first surface and the cross laminated film.

The cross laminated film can be an oriented cross laminated film. In an embodiment the oriented cross laminated film is a high density polyethylene (HDPE) oriented cross laminated film. In an embodiment, the HDPE oriented cross laminated film has a thickness of about 3.0 thousandths of an inch (mils).

The tie layer can be a polyolefin or polyolefin copolymer or blend thereof. In an embodiment, the tie layer is a propylene based elastomer blend. One blend is a blend with low density polyethylene (LDPE). In such a blend, the propylene based elastomer can be present at about 10 percent to about 60 percent by weight of the tie layer blend, and can be about 25 percent by weight of the blend, and LDPE can be present at about 40 percent to about 90 percent by weight of the tie layer blend, and can be about 75 percent by weight of the blend. The tie layer can be present or applied at about 5 lbs per ream to about 20 lbs per ream of membrane and can be at about 7 lbs per ream to about 10 lbs per ream.

The non-woven layer can be a polypropylene non-woven fabric. The fabric can have a basis weight of about 0.5 ounces per square yard (osy) to about 4.0 osy, and can be about 0.9 osy.

A waterproof membrane can be formed having first and second polypropylene non-woven layers having first and second surfaces, a HDPE oriented cross laminated film layer, and a tie layer between the first non-woven first surface and the oriented cross laminated film layer and between the second non-woven first surface and the oriented cross laminated film layer. The tie layer can be a propylene based elastomer or propylene based elastomer blend.

The first and second polypropylene non-woven layers can each have a basis weight of about 0.9 osy, the HDPE oriented cross laminated film layer can have a thickness of about 3.0 mils, and each tie layer can present at about 7 to about 10 lbs per ream of membrane. In such a membrane, the tie layers are a propylene based elastomer blend with LDPE with the propylene based elastomer present at about 25 percent by weight of the blend and LDPE present at about 75 percent by weight of the blend.

A method of making a waterproof membrane includes adhering a cross laminated film layer between first and second polypropylene non-woven layers having first and second surfaces. In such a method, the cross laminated film layer can be an oriented cross laminated film layer, such as a HDPE oriented cross laminated film layer. In such a method the adhering step can be carried out by applying a tie layer between the first non-woven layer and the oriented cross laminated film and applying a tie layer between the second non-woven layer and the oriented cross laminated film.

The adhering step can include laminating the first non-woven layer to the oriented cross laminated film layer at a side of the oriented cross laminated film layer and laminating the second non-woven layer to the oriented cross laminated film layer at an opposite side of the oriented cross laminated film layer. The laminating steps can be performed using extrusion lamination.

In an embodiment, a method of establishing a waterproof barrier between a substrate and a tiled wall includes applying on the substrate a waterproof membrane having a first non-woven layer with first and second surfaces, a cross laminated film layer, a second non-woven layer with first and second surfaces and a tic layer between the first non-woven first surface and the cross laminated film and the second non-woven first surface and the cross laminated film. Tile is then applied over the waterproof membrane. The method can include the steps of applying a coat of thinset adhesive on the substrate; applying the waterproof membrane to the thinset adhesive, applying a second coat of thinset on the membrane, and applying the tile to the coat of thinset adhesive.

These and other features and advantages of the present invention will be readily apparent from the following detailed description, in conjunction with the claims.

DESCRIPTION OF THE DRAWINGS

The benefits and advantages of the present invention will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein:

FIG. 1 is a cross-sectional view of a waterproof membrane with cross laminated film; and

FIG. 2 is a cross-sectional view of an exemplary use of the membrane in application of tile to a wall or floor.

DETAILED DESCRIPTION

While the present disclosure is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described one or more embodiments with the understanding that the present disclosure is to be considered an exemplification thereof and is not intended to be limited to the specific embodiment or embodiments illustrated.

FIG. 1 illustrates a waterproof membrane 10 with cross laminated film. An embodiment of the membrane 10 is formed as a laminate having a structure of ABCBA in which A is a non-woven sheet 12, Bis a polymeric tie resin layer 14 and C is an oriented cross laminated film 16.

One non-woven sheet 12 is a polypropylene (PP) non-woven fabric having a basis weight of about 0.5 osy to about 4.0 osy, and can be about 0.9 osy. A suitable material is Elite 100 Lt. Grey #49623 commercially available from Hanes Companies, Inc. Such a material has a basis weight of about 0.9 ounces per yard (osy) per ASTM D 3776M-09A, an elongation of about 75 percent in the machine direction and 85 percent in the cross direction per ASTM D 5034-09, a grab tensile strength of about 86 Newtons/2.54 centimeters (N/2.54 cm) in the machine direction and 70 N/2.54 cm in the cross direction per ASTM D 5034-09 and a trap tear strength of about 7 pounds (lbs) in the machine direction and 9.7 lbs in the cross direction per ASTM D 5733-09.

Other suitable materials for the non-woven sheet 12 include polyethylene terephthalate (PET), for example, a PET pointbond non-woven material. Other suitable materials will be recognized by those skilled in the art.

The polymeric tie layer 14 provides adhesion between the non-woven sheet 12 and the oriented cross laminated film 16 (discussed below). The tic layer can be a polyolefin or polyolefin copolymer or blend thereof. In an embodiment, the tie layer is a propylene based elastomer blend. One blend is a blend with low density polyethylene (LOPE). Tn such a blend, the propylene based elastomer can be present at about 10 percent to about 60 percent by weight of the tie layer blend, and can be about 25 percent by weight of the blend, and LOPE can be present at about 40 percent to about 90 percent by weight of the tie layer blend, and can be about 75 percent by weight of the blend. The tie layer can be present or applied at about 5 lbs per ream to about 20 lbs per ream of membrane and can be at about 7 lbs per ream to about 10 lbs per ream. One suitable LDPE is commercially available from Westlake Chemical Corporation under the designation EC808. Other suitable materials include LyondellBasell NA214.

One suitable propylene based elastomer is commercially available from Exxon-Mobil Chemical as Vistamaxx™ 6202. Other suitable materials include thermoplastic polyolefins, such as Adflex Z 108, commercially available from LyondellBasell Industries. In an embodiment, the tie layer 14 is formulated from a blend of about 75 percent (by weight) LDPE and 25 percent (by weight) propylene based elastomer. The specific formulation can vary as will be recognized by those skilled in the art.

One suitable cross laminated film 16 is an oriented cross laminated polyolefin, such as a high density polyethylene (HDPE) film commercially available from VALERON(g) Strength Films of Houston, Tex. The oriented cross laminated HDPE film 16 has a thickness of about 3.0 mils. The VALERON® Strength Films brand film is an HDPE material that is formed from a cross laminate of two film layers or plies that are each extruded and bias cut in a continuous spiral to obtain molecular orientation at an angle between 1 degree and 89 degrees with the machine direction. The bias cut film plies are then cross-laminated, and can be, although not necessarily, cross-laminated with an adhesive or polymer between the film layers to form a web. Such a film is disclosed and described in Barnes, U.S. Pat. No. 6,284,344, which is commonly assigned with the present application and is incorporated herein by reference. Other materials, such as polyethylene terephthalate (PET), polyolefins, including polypropylene (PP), polyamides and coextruded polymeric materials are contemplated for use as the oriented cross laminated film 16. Such films, for example, the VALERON(g) Strength Films brand film, may be provided as a material that includes more than two plies; such films arc within the scope and spirit of the present disclosure.

In a present membrane 10, the non-woven layer 12 is a polypropylene non-woven material in a basis weight of about 0.9 osy, the tie layer is, as noted above, a blend of 75 percent by weight LDPE and 25 percent by weight propylene elastomer. Each tie layer 14 is present at about 7-10 lbs per ream, and in an embodiment, about 8 lbs per ream of membrane 10, and the oriented cross laminated film 16 is a 3.0 mil VALERON® Strength Films brand film.

It is contemplated that the membrane 10 will be made in a lamination process. For example, in one extrusion lamination process, in a first-pass lamination, the non-woven material 12 a is laminated to the oriented cross laminated film 16 using about 7 to 10 lbs per ream of the tie layer 14 a blend forming a partially formed membrane. In a second-pass lamination, the non-woven material 12 b is laminated to the opposing side of the oriented cross laminated film 16, again using about 7 to 10 lbs per ream of the tie layer 14 b blend to form the ABCBA structure described above. Other processes and other lamination processes are also contemplated, including adhesives, solvent-less bonding and the like.

It has also been found that the tie layers 14 can be formulated from essentially 100 percent propylene elastomer (e.g., 100 percent Vistamaxx™ 6202) and that a membrane 10 formed as such functions well.

In one contemplated use, as illustrated in FIG. 2 , the membrane 10 is used as a waterproofing membrane behind wall or floor tile T in a shower or under a floor for waterproofing or to prevent reflection cracking. The membrane 10 is applied to the substrate S (e.g., gypsum board, cement board or the like) in the tile area with a thinset adhesive A1 (such adhesives will be recognized by those skilled in the art). After a sufficient drying/curing time (about 24 hours), the tile Tis adhered to the other side of the membrane 10 using thinset adhesive A2. It will be appreciated that the membrane 10 can be applied through corners, over surface irregularities, and in non-linear locations (e.g., curved or curvilinear surfaces) without the need for seams and the like.

In an embodiment, a method of establishing a waterproof barrier between a substrate and a tiled wall includes applying on the substrate a waterproof membrane having a first non-woven layer with first and second surfaces, a cross laminated film layer, a second non-woven layer with first and second surfaces and a tic layer between the first non-woven first surface and the cross laminated film and the second non-woven first surface and the cross laminated film. Tile is then applied over the waterproof membrane. The method can include the steps of applying a coat of thinset adhesive on the substrate, applying the waterproof membrane to the thinset adhesive, applying a second coat of thinset on the membrane, and applying the tile to the coat of thinset adhesive. The cross laminated film can be an oriented cross laminated film.

It has been found that the present membrane provides surprising flexibility and light weight in a high strength structure. The strength and physical properties provided by a flexible film, such as the VALERON® brand film, allows for significantly less polymer to be used between the non-woven surface layers. This permits a thinner structure which is more flexible than known products. In addition, this provides a membrane that is easier to handle and to apply to a work area. In that the film layer can be a relatively thin element (about 3.0 mils), there is reduced stiffness which makes it easier to embed the product in thinset adhesive applied to the wall structure and also allows the film to conform to comers, curvilinear surfaces, such as arches and the like, and surface irregularities. The light weight of the membrane 10 helps to prevent it from sliding down the wall during application due to its own weight.

In addition, the membrane provides an excellent barrier to water vapor. The oriented films, such as the HDPE based VALERON® brand film, provides an excellent barrier to water vapor which permits use in regular and steam showers. Known lower barrier elements require thicker polymer layers to meet the requirements for steam showers. This results in a thicker, less flexible and heavier membrane.

A sample of a membrane according to the present disclosure was compared to a sample of a commercially available waterproof membrane for use in areas that may be subjected to high moisture. The samples were tested for tensile break in the machine and transverse directions measured in pounds per inch (lbs/in) in accordance with standard ASTM D 882, tear propagation resistance (trouser tear) in the machine and transverse directions measured in pounds per inch (lbs/in) in accordance with standard ASTM D 1938, Toyo impact measured in kilogram centimeters (kg*cm) in accordance with a modified standard ASTM D 781 (mod) and water vapor transmission rate (WVTR) measured in US Perms (1 grain of water vapor per hour, per square foot, per inch of mercury) at 37.8C at 90% relative humidity, in accordance with standard ASTM E96—procedure E. The basis weight of each sample was also measured. The results are shown below in Table 1.

TABLE 1 COMPARISON OF VARIOUS PHYSICAL PROPERTIES FOR A PRESENT MEMBRANE AND A COMMERCIALLY AVAILABLE WATERPROOF MEMBRANE Commercially available Physical Present waterproof Property Method Units membrane membrane Basis wt. Lbs/ream 101 163 Tensile break ASTM D Lbs/in MD 32 31 882 TD 29 24 Tear ASTM D lbs MD 7.2 5.9 propagation 1938 TD 6.6 6.4 Toyo ASTM D Kg* cm 145 100 impact 781 (mod) WVTR ASTM E96- US Perms 37.8 C., <0.075 0.90 Proc. E 90% RH

As can be seen from the data of Table 1, above, a membrane in accordance with the present disclosure has a number of advantages over the commercially available waterproof membrane. The present membrane is lighter in weight and stronger in each category tested. In addition, it exhibits a lower water vapor transmission rate when tested at 37.8C and at a relative humidity of 90%.

The tie layer or resin, e.g., the elastomer used to laminate the non-woven and oriented cross laminated film layers, provides excellent adhesion to both the HDPE based films the PP or other-based non-woven material. Again, the specific formulation of the tie layer can be varied to meet the requirements and suitability of the adhesion needs between the oriented cross laminated film and the non-woven material. The elastomer tie layer reduces the stiffness of the laminating layers further enhancing the flexibility of the membrane.

In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular.

From the foregoing it will be observed that numerous modification and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present membrane. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims. 

What is claimed is:
 1. A waterproof extrusion laminated flexible membrane for waterproofing an irregularity on a substrate supporting a finished surface, comprising: first and second polypropylene non-woven layers, each having first and second surfaces; a water impermeable HDPE oriented cross laminated film layer, the cross laminated film layer having a thickness of about 3.0 mils; a first tie layer between the first non-woven first surface and the cross laminated film layer; and a second tie layer between the second non-woven first surface and the cross laminated film layer; wherein: the first and second tie layers are each present at about 7 to about 10 lbs per ream of membrane and each comprise a propylene based elastomer blend and LDPE, wherein the propylene based elastomer is present at about 25 percent by weight of the blend and LDPE is present at about 75 percent by weight of the blend; the first and second polypropylene non-woven layers each have a basis weight of about 0.9 osy; and the flexible membrane may be seamlessly applied to the irregularity on the substrate for waterproofing.
 2. A flexible water-proofing membrane for use with thinset mortar, comprising: a cross-laminated film layer comprising: an upper surface; a lower surface: a thickness between the upper and lower surfaces of about 3.0 mils; and two plies of high density polyethylene mechanically oriented to each other; a first polymeric laminating layer applied to the upper surface of the cross-laminated film layer; a first non-woven layer comprising: an inner surface extrusion laminated to the first laminating layer; and an outer surface configured to adhere to thinset mortar; a second polymeric laminating layer applied to the lower surface of the cross-laminated film layer; and a second non-woven layer comprising: an inner surface extrusion laminated to the second laminating layer; and an outer surface.
 3. The flexible water-proofing membrane of claim 2, wherein the outer surface of the second non-woven layer is configured to adhere to thinset mortar applied to a board-formed material.
 4. The flexible water-proofing membrane of claim 2, further comprising an adhesive applied to the outer surface of the second non-woven layer and configured to adhere to a board-formed material.
 5. The flexible water-proofing membrane of claim 2, wherein the membrane is rolled around a roll for storage and dispensing in roll form.
 6. The flexible water-proofing membrane of claim 2, wherein at least one of the first and second non-woven layers comprises a polypropylene non-woven fabric.
 7. The flexible water-proofing membrane of claim 2, wherein the polypropylene non-woven fabric has a basis weight of about 0.5 osy to about 4.0 osy.
 8. A water-proofing sealer for a penetration in a board-formed building material, comprising: a first non-woven layer comprising: an outer surface configured to span the penetration by adhering to a surface of the board-formed building material surrounding the penetration; and an inner surface; a cross-laminated film layer comprising: an upper surface; a lower surface extrusion laminated to the inner surface of the first non-woven layer with a first polymeric laminating layer; a thickness between the upper and lower surfaces of about 3.0 mils; and two plies of high density polyethylene mechanically oriented to each other; a second non-woven layer comprising: an outer surface configured to adhere to thinset mortar, and an inner surface extrusion laminated to the upper surface of the cross-laminated film layer with a second polymeric laminating layer.
 9. The water-proofing sealer of claim 8, wherein the outer surface of the first non-woven layer is configured to adhere with thinset mortar to the surface of the board-formed building material surrounding the penetration.
 10. The water-proofing sealer of claim 8, further comprising an adhesive applied to the outer surface of the first non-woven layer, the adhesive configured to adhere to the surface of the board-formed building material.
 11. The water-proofing sealer of claim 8, wherein at least one of the first and second non-woven layers comprises a polypropylene non-woven fabric.
 12. The water-proofing sealer of claim 8, wherein the polypropylene non-woven fabric has a basis weight of about 0.5 osy to about 4.0 osy.
 13. A water-proofing sealer band for use with board-formed building materials, comprising: a cross-laminated film layer comprising: an upper surface; a lower surface; a thickness between the upper and lower surfaces of about 3.0 mils; and two plies of high density polyethylene mechanically oriented to each other; a first polymeric laminating layer applied to the lower surface of the cross-laminated film layer; a first non-woven layer comprising: an inner surface extrusion laminated to the first laminating layer; and an outer surface configured to span a seam, joint or corner and adhere to: a first surface on a first piece of board-formed material at the seam, joint, or corner between the first piece of board-formed material and a second piece of board-formed material, and a second surface on the second piece of board-formed material to prevent moisture from entering between the first and second pieces of board-formed materials; a second polymeric laminating layer applied to the upper surface of the cross-laminated film layer; and a second non-woven layer comprising: an outer surface configured to adhere to thinset mortar, and an inner surface extrusion laminated to the second laminating layer.
 14. The water-proofing sealer band of claim 13, wherein the sealer band comprises a width of between about 3 and 9 inches.
 15. The water-proofing sealer band of claim 13, wherein outer surface of the first non-woven layer is configured to adhere to the first and second surfaces forming the seam, joint or corner using thinset mortar.
 16. The water-proofing sealer band of claim 13, further comprising an adhesive pre-applied to the outer surface of the first non-woven layer, the pre-applied adhesive configured to adhere to the first and second surfaces forming the seam, joint or corner.
 17. The water-proofing sealer band of claim 13, wherein the sealer band is rolled around a roll for storage and dispensing in roll form.
 18. The water-proofing sealer band of claim 13, wherein the sealer band comprises a sheet form.
 19. The water-proofing sealer band of claim 13, wherein at least one of the first and second non-woven layers comprises a polypropylene non-woven fabric.
 20. The water-proofing sealer band of claim 13, wherein the polypropylene non-woven fabric has a basis weight of about 0.5 osy to about 4.0 osy. 